Process for preparing bromine- containing polymers

ABSTRACT

The invention provides a process for preparing bromine-containing polymers, comprising a Friedel-Crafts alkylation reaction of pentabromobenzyl halide with a polymer reactant which contains one or more six-membered aromatic ring(s) in its repeat unit, in the presence of at least one Friedel-Crafts catalyst. The so-formed bromine-containing polymers, having pendent —CH 2 C 6 Br 5  groups attached to at least a portion of the six-membered aromatic rings of the polymer, with a carbon ring atom of said six-membered aromatic ring being bonded to the aliphatic carbon of said —CH 2 C 6 Br 5  pendent group, are also provided. These bromine-containing polymers are useful as flame retarding agents.

This application is a divisional of U.S. application Ser. No.15/323,869, which is the U.S. national stage of InternationalApplication No. PCT/IL2015/050700 filed Jul. 7, 2015, which claims thepriority benefit of U.S. 62/021,722 filed Jul. 8, 2014, the entirerespective disclosures of which are incorporated herein by reference.

The present invention provides a novel class of high molecular weightpolymers having pendent pentabromobenzyl groups, which are suitable foruse as flame retardants in flammable materials (e.g., polyamide,polypropylene and acrylonitrile-butadiene-styrene compositions).

Brominated compounds are known to be highly effective as flameretardants, and in many cases they constitute the only viable option forreducing the fire risk of synthetic materials. There exists a need todevelop new, polymeric high molecular weight, brominated flameretardants. It is postulated that the higher the molecular weight of thebrominated flame retardant, the lower is its volatility and its abilityto bio-accumulate in living tissues.

Low molecular weight compounds containing a pentabromobenzyl moiety areknown in the art. Pentabromobenzyl acrylate (EP 481126),pentabromobenzyl terephthalate (DE 33 20 333) and pentabromobenzyltetrabromophthalate (EP 47866) have been reported to be useful in flameretarded polymer compositions. Furthermore, poly (pentabromobenzylacrylate) is used as a flame retardant agent in flammable materials.Hereinafter, the pentabromobenzyl group is sometimes described by itsmolecular structure:

or its molecular formula —CH₂C₆Br₅.

In a co-assigned international patent application PCT/IL2014/000002 (=WO2014/106841), the use of pentabromobenzyl halide as alkylating reagentin Friedel-Crafts alkylation reaction of low molecular weight aromaticcompounds such as alkyl-substituted benzene (e.g., toluene, xylene,ethylbenzene) and diphenylalkane has been illustrated.

We have now found that the —CH₂C₆Br₅ group can be incorporated intoaromatic rings-containing polymers via a synthetic pathway based on anelectrophilic aromatic C-alkylation (also known as Friedel-Craftsalkylation), to produce bromine-rich polymers useful as flameretardants. The present invention thus provides a polymer comprisingsix-membered aromatic rings, either in the form of side chains (like inpolystyrene) or as part of its backbone chain (like in poly(phenylether)), characterized in that pendent —CH₂C₆Br₅ groups areattached to at least a portion of said six-membered aromatic rings ofthe polymer, with a carbon ring atom being bonded to the aliphatic(benzylic) carbon of said —CH₂C₆Br₅ pendent group. The pentabromobenzylgroup-containing polymers of the invention have high molecular weight,preferably not less than 1,800, e.g., not less than 3,500(e.g., >6,000), their bromine content is preferably not less than 60%,they are insoluble in water and they are also quite stable againsthydrolysis and/or decomposition.

It should be noted that the invention pertains also to copolymers havingtwo or more different types of repeat units, provided, of course, thatat least one of said repeat units contains an aromatic ring with a—CH₂C₆Br₅ pendent group bonded through its benzylic carbon to a carbonatom of the aromatic ring in said at least one repeat unit.

The polymers of the invention fall into two broad categories: (I)polymers where the aromatic rings (bearing the —CH₂C₆Br₅ moiety)constitute side groups, and (II) polymers where the aromatic rings(bearing the —CH₂C₆Br₅ groups) constitute part of the polymer backbonechain, as illustrated more specifically by Formulas I and II,respectively:

In the polymer of Formula I, the benzene ring bearing —CH₂C₆Br₅ group(s)constitutes a side group; R is Br or a linear or branched aliphaticchain, k is independently an integer from 0 to 4, preferably 0 or 1, yis an integer from 1 to (5-k), A=null, ethylene —CH₂CH₂—, butylene—CH₂CH═CHCH₂—; propylene —CH(CH₃)CH₂—; isoprene —CH₂—CH═C(CH₃)CH₂—, andn and m are the number of units in the polymer chain (e.g., in FormulaI, 3≤n≤1000 and m=0 or 0.1≤m≤0.8n; in Formula II, 3≤n≤1000).

In the polymer of Formula II, the benzene ring bearing —CH₂C₆Br₅group(s) constitutes part of the backbone chain; X=null, O, S, CH₂,CH₂CH₂, and n is the number of units in the polymer chain.

It should be noted that the representation of the polymers of theinvention by the conventional notation —[—B—]-n is not intended to implythat each and every unit in the polymer contains a pendent —CH₂C₆Br₅group.

The polymer compounds of the invention are prepared by reactingpentabromobenzyl halide, especially pentabromobenzyl bromide (chemicallynamed 1-(bromomethyl)-2,3,4,5,6-pentabromobenzene and abbreviated hereinPBBBr) with a polymer starting material which comprises at least onesix-membered aromatic ring in its repeat unit, as set out above, in thepresence of a suitable Friedel-Crafts catalyst (Lewis acids) such asAlCl₃, AlBr₃, GaCl₃, FeCl₃, SnCl₄, SbCl₃, ZnCl₂, CuCl₂ and HF, or amixture thereof. The use of AlCl₃, either alone or in combination withone or more other catalysts, especially SnCl₄, is preferred. Forexample, a mixture consisting of AlCl₃ and SnCl₄, in 1:3-3:1 molarratio, e.g., around 1:1, has been successfully used to catalyze thereaction.

Thus, another aspect of the invention is a process for preparingbromine-containing polymers, comprising a Friedel-Crafts alkylationreaction of pentabromobenzyl halide (HaICH₂C₆Br₅, wherein HaI indicateshalide such as chloride or bromide) with a polymer reactant having oneor more six-membered aromatic ring(s) in its repeat unit, wherein saidreaction takes place in a solvent in the presence of at least oneFriedel-Crafts catalyst. The so-formed products (Formulas I and II) arecharacterized by the presence of bonds between carbon ring atoms of thearomatic rings of the polymer, and the benzylic carbon of thepentabromobenzyl groups.

Regarding the pentabromobenzyl bromide starting material, it iscommercially available (e.g., from ICL-IP) or it can be prepared bymethods known in the art (e.g., U.S. Pat. Nos. 6,028,156 and 7,601,774),according to a route of synthesis involving the aromatic bromination oftoluene, for example in halogenated solvent(s), using elemental bromine,in the presence of a Lewis acid catalyst, e.g. AlCl₃, to formpentabromotoluene (abbreviated herein 5-BT), which is then brominated atthe benzylic carbon using elemental bromine and a radical source e.g.azobisisobutyronitrile, as illustrated by the following scheme (see U.S.Pat. No. 7,601,774):

Regarding the starting material which undergoes the aromaticsubstitution reaction, namely, electrophilic aromatic C-alkylationaccording to the invention, it is a polymer comprising an aromatic ringin its repeat unit (or in at least one of its repeat units, in the caseof a copolymer starting material). Preferably, the polymer startingmaterial is represented by formulas III or IV:

In Formula III, R is a linear or branched aliphatic chain or bromine, kis independently an integer from 0 to 4, preferably 0 or 1, A=null,ethylene —CH₂CH₂—, butylene —CH₂CH═CHCH₂—; propylene —CH(CH₃)CH₂—; orisoprene —CH₂—CH═C(CH₃)CH₂—, n and m are the number of repeat units inthe polymer chain.

In formula IV, X=null, O, S, CH₂, CH₂CH₂, and n is the number of repeatunits in the polymer chain.

Exemplary starting materials of formula III include:

Polystyrene, where k=0, A=null and m=0;

Styrene copolymers, such as poly(styrene-co-ethylene), where k=0 and Ais —CH₂CH₂—; poly(styrene-co-butadiene), where k=0 and A is—CH₂CH═CHCH₂—, (CAS 9003-55-8); and poly(styrene-co-isoprene), where k=0and A is —CH₂—CH═C(CH₃)CH₂—, (CAS 250038-32-8).

Exemplary starting materials of formula IV include poly(phenyl ether),where X═O.

The Friedel-Crafts alkylation reaction according to the invention takesplace in a solvent or in a mixture of solvents, e.g., in a halogenatedaliphatic hydrocarbon which is preferably selected from the groupconsisting of dichloromethane (DCM), dibromomethane (DBM),bromochloromethane and dichloroethane (DCE). The molar ratio between thepolymer starting material and HaICH₂C₆Br₅ is suitably adjusted tosatisfy the desired degree of substitution on the aromatic ring(s) ofsaid polymer starting material. In general, it is desired to attach notless than one —CH₂C₆Br₅ group to each six-membered aromatic ring presentin the polymer starting material. The amount of the catalyst, e.g. AlCl₃or a mixture of catalysts, is preferably between 0.5% wt/wt and 2% wt/wtrelative to the HaICH₂C₆Br₅ (e.g., PBBBr amount). The reaction is rununder anhydrous conditions.

A reaction vessel is charged with a solvent, the polymer startingmaterial (e.g., polystyrene), HaICH₂C₆Br₅ (e.g., PBBBr) and thecatalyst(s). The reactants are dissolved under heating, following whichthe catalyst is added. The polymer starting material and HaICH₂C₆Br₅ maybe fed either simultaneously or successively to the reaction mixture.For example, in some cases it may be more expedient first to dissolvethe polymer starting material in the solvent, and on formation of aclear solution, to proceed with the addition of the HaICH₂C₆Br₅ (e.g.,PBBBr) to the solution, or addition of the polymer solution to theHaICH₂C₆Br₅. The reaction reaches completion at a temperature of notless 40° C., e.g. from 40° C-90° C., more specifically from 60° C-90° C.In general, the reaction time is from 2 to 8 hours. The Friedel-Craftsalkylation reaction is accompanied by the generation of hydrogenbromide. The end of the reaction is indicated by either the completeconsumption of the PBBBr (its disappearance can be determined by gaschromatography analysis) or by the cessation of hydrogen bromideevolution.

The product is isolated from the reaction mixture by means ofconventional techniques. The reaction mixture is repeatedly washed withwater, aqueous sodium bisulfite (SBS) or alkaline solutions (e.g.,sodium carbonate or sodium hydrogen carbonate), whereby excess catalystis destroyed. In the event that the polymer product does notspontaneously precipitate from the halogenated aliphatic hydrocarbonreaction solvent, then its precipitation can be induced by combining thereaction mixture with a non-solvent i.e., a solvent in which the productis essentially insoluble. Polar solvents such as acetone and loweralcohols such as isopropanol, which are sufficiently miscible withhalogenated aliphatic hydrocarbon, are useful as non-solvents. Oncooling, the polymer product precipitates from mixtures of halogenatedaliphatic hydrocarbon and acetone or isopropanol. The polymer product iscollected by filtration, and optionally washed and dried.

The invention also relates to the use of pentabromobenzyl halideHaICH₂C₆Br₅ (e.g., PBBBr) as an alkylation reagent in a Friedel-Craftsalkylation of a polymer having an aromatic ring-containing repeat unit,such as those identified by Formulas III and IV. Preferred polymersstarting materials are polystyrene grades with weight average molecularweight from 170000 to 350000 and polyphenylether grades with weightaverage molecular weight from 400 to about 350000.

In a preferred embodiment, the invention provides a process comprisingcharging a reaction vessel with a solvent (e.g., halogenated aliphatichydrocarbon), a polymer starting material selected from the groupconsisting of polystyrene and poly(phenylether), pentabromobenzyl halideHaICH₂C₆Br₅ (e.g., PBBBr) and one or more catalysts used forFriedel-Crafts alkylation, allowing the Friedel-Crafts alkylation toreach completion and recovering bromine-containing polymer product,i.e., with pendent —CH₂C₆Br₅ groups. Preferably, the number of moles ofHaICH₂C₆Br₅ used is the reaction is not less than the total number ofmoles of the aromatic rings in the polymer starting material. Forexample, if a grade of polystyrene with an weight average molecularweight of about 200,000 is used, then the average number of repeat unitsin the polymer chain is approximately 2000 (as the molecular weight ofthe repeat unit of polystyrene is around 100). Thus, not less than onemol of HaICH₂C₆Br₅ would be used per 0.0005 mol of the polystyrenestarting material.

Preferred bromine-containing polymers of the invention are those ofFormula I, with k=0, m=0 and y=1, as represented by Formula V:

Pentabromobenzyl-substituted polystyrene provided by the invention ischaracterized by bromine content of not less than 60%, e.g., from 65 to70% by weight. The thermal stability profile of preferredpentabromobenzyl-substituted polystyrene of the invention, as indicatedby thermogravimetric analysis (TGA), which measures the weight loss of asample as sample temperature is increased, is typically as follows:

temperature T1 ≥ 360° C. T2 ≥ 370° C. T3 ≥ 380° C. % weight loss 2.0 5.010.0

Other preferred bromine-containing polymers of the invention are thoseof Formula II, with X═O and y=2, as shown by Formula VI:

Pentabromobenzyl-substituted polyphenylether provided by the inventionis characterized by bromine content of not less than 70% e.g., from 70to 75% by weight. The thermal stability profile of preferredpentabromobenzyl-substituted polyphenylether of the invention istypically as follows:

temperature T1 ≥ 345° C. T2 ≥ 355° C. T3 ≥ 365° C. % weight loss 2.0 5.010.0

Especially preferred bromine-containing polymer of the invention ispentabromobenzyl-substituted polystyrene with bromine content from 65 to70% by weight, showing 5% weight loss at a temperature equal to orhigher than 370° C. (preferably >375° C.) and/or 10% weight loss at atemperature higher than 380° C. (preferably >385° C.), when subjected toTGA at heating rate of 10° C./min. Bromine content of the product ismeasured by the Parr Bomb method, involving the decomposition ofbromine-containing organic compounds to give bromides, followed byargentometric titration, as described further below. The experimentalresults reported below indicate that pentabromobenzyl-substitutedpolystyrene is successfully added to plastic materials to reduce theirflammability.

It is possible to incorporate additional bromine atoms into the polymersof the invention by subjecting the bromine-containing polymers producedby the Friedel-Crafts alkylation to a bromination reaction (e.g., withelemental bromine). One specific embodiment of the invention istherefore concerned with a process for preparing bromine-containingpolymers, comprising:

(i) a Friedel-Crafts alkylation reaction of pentabromobenzyl halide witha polymer reactant having one or more six-membered aromatic ring(s) inits repeat unit, wherein said reaction takes place in a solvent in thepresence of at least one Friedel-Crafts catalyst, to obtainpentabromobenzyl-substituted polymer; and

(ii) subjecting the so-formed pentabromobenzyl-substituted polymer tobromination reaction.

The bromination reaction may also take place in halogenated hydrocarbon,or a mixture of halogenated hydrocarbons, such as those used for thealkylation reaction. The reaction vessel is charged with the solvent(s)and pentabromobenzyl-substituted polymer (e.g.,pentabromobenzyl-substituted polystyrene). Elemental bromine and asuitable catalyst (e.g., one or more Lewis acid catalysts as identifiedabove, especially AlCl₃ and mixtures thereof with other catalysts) arecharged to the reaction vessel. Elemental bromine is gradually added tothe reaction vessel in an amount sufficient to provide the degree ofbromination sought, e.g., one or two bromine atoms per aromatic ring inthe polymer. The completion of the bromination reaction is indicated bythe cessation of the HBr evolution. The product is recovered byconventional methods. In this way it is possible to producebromine-containing polymer of Formula I, with the benzene rings bearing—CH₂C₆Br₅ group(s) and also bromine atoms (i.e., R is Br and k=1 or 2),with bromine content exceeding 70% (from 70 to 75% by weight).

Thus, the bromine-rich polymers of the invention are useful as flameretardant agents in a flammable material. Accordingly, another aspect ofthe present invention is a flame-retarded composition which comprises aflammable material and the novel polymer of the invention. For example,the bromine-containing polymers of the invention can be used to reducethe flammability of polyamide, polypropylene andacrylonitrile-butadiene-styrene (ABS).

A flame-retarded composition of the invention comprises an effectiveflame-retarding amount of the novel bromine-containing polymer of theinvention, e.g., the compounds of Formula I and II, and specifically, Vand VI. The concentration the bromine-containing polymer of theinvention in the plastic formulation is adjusted to secure a brominecontent of least 5 wt %, and preferably at least 10 wt %, for example,from 10 to 25% by weight, and more specifically, from 10 to 20% byweight (relative to the total weight of the flame-retarded plasticformulation).

Other conventional additives may also be included in the formulation.For example, an inorganic compound (typically a metal oxide) capable ofcooperating with the novel bromine-containing polymer is preferably alsoincorporated into the formulation. A preferred example of a suitableinorganic compound, which is generally considered as an “inorganicsynergist”, is antimony trioxide.

Specifically, the novel bromine-containing polymers of the inventiondisplay good activity in polyamide. Polyamide-based composition of theinvention comprises at least 30% polyamide, e.g., between 40% and 70% wt%. The polyamide formulation further comprises reinforcing fillers,namely, glass fibers, which are typically pre-coated prior to their useby methods known in the art in order to improve their compatibility withthe polyamide matrix. Such modified forms of glass fibers are availablein the market, e.g., GF Chop Vantage 3660 from PPG. The glass fiberscomprise filaments with diameters in the range from 2μ to 20μ, and areapplied in the form of pieces with lengths in the range from 2 to 10 mm,e.g., from 3 to 4.5 mm. For example, the major constituents of glassfibers applied for reinforcing polyamide are alumino-borosilicates; sucha type of glass is known as E-glass. The concentration of the glassfibers is from 5% to 40% of the total weight of the polyamidecomposition.

In addition to the polyamide, the reinforcing fillers, thebromine-containing polymer (e.g., compounds of Formula I or II) andantimony trioxide, the polyamide formulation of this invention mayfurther contain lubricants, antioxidants (e.g., of a hindered phenol orphosphite type), pigments, UV stabilizers and heat stabilizers. Theconcentration of each of the conventional additives listed above istypically between 0.05 and 10 wt %.

The polyamide compositions are produced by melt-mixing the components,e.g., in a co-kneader or twin screw extruder, wherein the mixingtemperature is in the range from 200 to 300° C. For example, thepolyamide, the bromine containing flame retardant and the conventionaladditives (with the exception of the glass fibers) are dry blended andthe blend is fed to the extruder throat. The glass fibers are the lastto be added, i.e., downstream.

Preferred polyamide compositions of the invention comprise 100parts-by-weight of polyamide (e.g., polyamide 6,6); from 40 to 70parts-by-weight of glass fibers; from 5 to 50 parts-by-weight ofpentabromobenzyl-substituted polystyrene of Formula V; and from 3 to 15parts-by-weight of an inorganic synergist (e.g., Sb₂O₃).

The novel bromine-containing polymers of the invention also demonstrategood activity in reducing the flammability of polypropylene.Polypropylene composition of the invention preferably comprises apolypropylene copolymer in an amount of not less than 50 wt % (relativeto the total weight of the composition), e.g., from 50 to 85 wt %, morespecifically from 50 to 70 wt %. Suitable polypropylene impactcopolymers which can be used in the present invention can be in the formof block copolymers comprising a first block (or phase), which isessentially the polypropylene homopolymer component and a second block(or phase), which is an ethylene-propylene copolymer component. Apolypropylene impact copolymer is produced by means of sequentialpolymerization reactions under conditions known in the art. The firstreaction produces the homopolymer component and the second reactionproduces the copolymer component. Thus, the copolymer component ischemically incorporated within the matrix of the homopolymer component.Different grades of polypropylene impact copolymers in the form of blockcopolymers are commercially available (Carmel Olefins, Israel, under thename Capilene® SE 50E, TR 50 and SL 50). Impact modified polypropylenescan be prepared by admixing a polypropylene homopolymer and a rubber.The compounds of the invention can be used to reduce the flammability ofeither filler-free or filler-containing polypropylene-basedformulations.

Preferred polypropylene compositions of the invention comprise 100parts-by-weight polypropylene copolymer; from 5 to 50 parts-by-weightpentabromobenzyl-substituted polystyrene of Formula V and from 2 to 20parts-by-weight of an inorganic synergist (e.g., Sb₂O₃).Filler-containing polypropylene further comprises from 5 to 25parts-by-weight talc, added either in a powder form or in the form ofmasterbatch pellets.

ABS compositions of the invention preferably comprise not less than 50wt % ABS (relative to the total weight of the formulation), e.g., from50 to 85 wt % ABS. The term ABS refers in the context of the presentinvention to copolymers and terpolymers that include the structuralunits corresponding to (optionally substituted) styrene, acrylonitrileand butadiene, regardless of the composition and method of production ofsaid polymers. Characteristics and compositions of ABS are described,for example, in the Encyclopedia of Polymer Science and Engineering,Volume 16, pages 72-74 (1985). ABS with MFI between 1 and 50 g/10 min(measured according to ISO 1133 at 220° C./10 kg) are used.

The ABS formulation according to the present invention also includes oneor more anti-dripping agents such as polytetrafluoroethylene(abbreviated PTFE) in a preferred amount between 0.025 and 0.4 wt %,more preferably between 0.025 and 0.3 wt %, and even more preferablybetween 0.05 and 0.2 wt %. PTFE is described, for example, in U.S. Pat.No. 6,503,988.

The plastic formulations set forth above are readily prepared by methodsknown in the art. The various ingredients of the formulation are blendedtogether, according to their respective amounts. The ingredients may befirst dry blended using suitable mixing machines, such as Henschelmixer. The resulting mixture may then be processed and compounded toform homogeneous pellets, for example, by using a twin screw extruder.The pellets obtained are dried, and are suitable for feed to an articleshaping process such as injection molding. Other blending and shapingtechniques can also be applied. Articles molded from the polymerformulations form another aspect of the invention.

EXAMPLES Methods

The TGA analysis was performed by a Mettler-toledo instrument model 850.˜10 mg sample were heated in aluminum oxide crucible from 35° C. toabout 700° C. with heating rate of 10° C./min in nitrogen atmosphere.

Bromine content of the compounds is measured by the Parr Bomb method.The sample (˜0.08-0.12 g) is placed in a peroxide bomb vessel. Sucrose(0.5 g) is added and the full dipper of sodium peroxide is also added.The sample is subjected to oxidizing with sodium peroxide while a burnerflame is applied to the bottom of the bomb; the bomb is heated up toabout 200° C. and the burner is then turned off. The bomb is placed incold water (2 liters). Gaseous products are absorbed by the alkalinemixture and are retained within the bomb, mostly in the form of sodiumbromide. The content of the bomb is then combined with warm water.Hydrazine sulfate is added to destroy residual sodium peroxide. Nitricacid is added in portions, until the solution is completely neutralizedand becomes acidic. The solution is cooled to room temperature and thensubjected to titration with AgNO₃ (0.1 N) to determine bromine content.

Example 1 Reaction of Polystyrene with PBBBr using AlCl₃ and SnCl₄

DBM (1.8 L) and polystyrene with MW of 170000-350000 (104.15 g) wereplaced in a 2 L reactor fitted with a mechanical stirrer, thermometer,condenser, HBr trap and N₂ inlet. The mixture was heated to 66° C. togive a clear solution. PBBBr (565.5 g) was then dissolved in thesolution. AlCl₃ (3.1 g) and SnCl₄(4.8 g) were added and the mixture washeated to 84° C., following which the vigorous evolution of HBr started.The mixture was heated at 80° C. for about 6 hours until the PBBBrdisappeared (by GC or HPLC). The reaction mixture was washed threetimes: with water (1.5 L), saturated NaHCO₃ solution (1.5 L) to givepH=7, and again with water (1.5 L), taking 30 minutes for each washing.After that, the reaction mixture was added dropwise to acetone (6 L) toinduce precipitation. The reaction mixture was cooled to 20° C. and thesolid was filtered off and dried in an oven at 105° C. under reducedpressure for 12 hours, to give 509 g, corresponding to an ˜86% yield,based on PBBBr. According to elemental analysis, the content of bromineis about 68%, corresponding to about one PBBBr molecule per aromaticring. The TGA profile of the product is tabulated below:

Temperature T1 = 365° C. T2 = 381° C. T3 = 391° C. % weight loss 2.0 5.010.0

Example 2 Reaction of Polystyrene with PBBBr using AlCl₃

The procedure of Example 1 was repeated, but using PBBBr (27.1 g),polystyrene (10.0 g), AlCl₃ (0.2 g) and dichloroethane (100 ml) as thesolvent. The weight of the product was 24.0 g, corresponding to ·72%yield, based on PBBBr. The content of bromine is about 60.0%.

Example 3 Reaction of Polyphenylether with PBBBr

Polyphenylether [Santovac 7, available from Santolubes LLC, MW˜450 (30g)], PBBBr (366.4 g) and DBM (700 ml) were placed in a 1 L reactorfitted with a mechanical stirrer, thermometer, condenser, HBr trap andN₂ inlet. The mixture was heated to 70° C. and AlCl₃ (3.5 g) was addedby portions. The mixture was stirred at 90° C. until the PBBBrdisappeared (5-6 h). The reaction mixture was washed at 50° C. withwater (250 ml) and SBS (2.5 ml, ˜28%), water (250 ml), 5% Na₂CO₃ (250ml) and water (250 ml), taking 20 minutes for each washing. The solvent(˜150 ml) was evaporated under reduced pressure. The remainder, heatedat 40-50° C., was added dropwise to IPA (450 ml) at 50° C., over 1 h,under vigorous stirring. The mixture was stirred at 50° C. for 1 h thencooled to 18° C. The solid was filtered off and washed with IPA (150 ml)on the filter. The solid was dried in the oven at 105° C., and at 150°C. under reduced pressure, for 3 and 7 hours respectively, to give awhite powder product (318 g, corresponding to ˜92% yield, based onPBBBr). The content of bromine is about 75.0%. The TGA profile of theproduct is tabulated below:

Temperature T1 = 351° C. T2 = 368° C. T3 = 375° C. % weight loss 2.0 5.010.0

Example 4 Bromination of the Product from Example 1

DBM/DCM (1495 g/96 g) and product of Example 1 (191.3 g) were placed ina 2 L reactor fitted with a mechanical stirrer, a dropping funnel,thermometer, condenser, HBr trap and N₂ inlet. The mixture was heated to60° C. to give a clear solution. Br₂ (38.2 g) was then added dropwise tothe solution over 0.5 h. AlCl₃ (1.0 g) and SnCl₄ (2.0 g) were added andthe mixture was heated to 65° C. and additional Br₂ (76.4 g) was addeddropwise, following which the vigorous evolution of HBr started. Themixture was heated at 65° C. for about 6 hours until the HBr evaluationwas observed (by titration). The reaction mixture was washed: with water(1.0 L), saturated NaHCO₃ solution (1.0 L) and again with water (1.0 L)to give pH=7, taking 30 minutes for each washing.

After that, the reaction mixture was added dropwise to isopropanol (1.5L) to induce precipitation. The reaction mixture was cooled to 20° C.and the solid was filtered off and dried in an oven at 105° C. underreduced pressure for 12 hours, to give 218 g, corresponding to an -89%yield.

According to analysis, the content of bromine is about 72%,corresponding to about two bromine atoms per aromatic ring. The TGAprofile of the product is tabulated below:

Temperature T1 = 267° C. T2 = 330° C. T3 = 375° C. % weight loss 2.0 5.010.0

In the studies reported in the following examples, the ability ofpentabromobenzyl-substituted polystyrene of Example 1 to reduce theflammability of different thermoplastics was evaluated. Test specimenswere prepared and subjected to the following tests:

Flammability Test

The flammability test was carried out according to theUnderwriters-Laboratories standard UL 94, applying the vertical burn onspecimens of 0.8 mm or 1.6 mm thickness.

Mechanical Properties

Impact strength was measured using the Izod notched test according toASTM D-256-81, using pendulum impact tester type 5102 (Zwick).

Tensile properties (tensile strength, tensile modulus, elongation atbreak) were measured in Zwick 1435 material testing machine according toASTM D-638-95 (v=5 mm/min).

Other Properties

HDT (heat distortion temperature; this is the temperature at which apolymer sample deforms under a specific load) was measured according toASTM D-648-72 with load of 1820 kPa and heating rate of 120° C./hour;the instrument is HDT/Vicat-plus from Davenport, Lloyd instruments.

MFI (melt flow index) was determined according to ASTM D1238 (230°C./2.16 kg for PP; 250° C./1.2 kg for polyamide); the instrument isMeltflixer 2000 from Thermo Hake.

Example 5 (Comparative) and Example 6 (of the Invention) V-0 RatedPolyamide 6,6 Formulation

In this set of examples, pentabromobenzyl-substituted polystyrene ofExample 1 was tested to evaluate its ability to reduce the flammabilityof polyamide 6,6. For the purpose of comparison, correspondingformulation was also prepared, where the flame retarding agent wasanother bromine-containing polymer (FR-803P; brominated polystyrenecommercially available from IC-IP).

Ingredients Used to Prepare the Compositions

The materials employed in the experimental work are set out in Table 1(the abbreviation “FR” indicates flame retardant):

TABLE 1 Product (manufacturer) description function P-50FL (Nilit)Polyamide 66 Plastic matrix GF Chop Vantage Glass fibers Reinforcingagents 3660 (PPG) FR-803P (ICL-IP) Brominated polystyrene FR Product ofPentabromobenzyl-substituted FR Example 1 polystyrene AO M-0112 Antimonytrioxide masterbatch FR-synergist (Kafrit) which contains 80% by weightSb₂O₃ Ca stearate (Ciba) Calcium Stearate Lubricant Acrawax CNitrogen-containing, hindered Antioxidant & heat (Lonza) phenolstabilizer Irganox 1171B N,N′ ethylene bisstearamide Antioxidant & heat(Ciba) stabilizer

Preparation of Polyamide Compositions and Test Specimens

The ingredients were compounded in a twin-screw co-rotating extruder(Berstorff ZE25) with L/D=32. The polyamide, the bromine-containingflame retardant and all other additives - with the exception of glassfibers—were weighed and mixed, and the resultant blend was fed into themain feeding port of the extruder. The glass fibers were fed into thefifth section of the extruder via lateral side feeding. A settemperature profile of 250-260-265-265-265-270-275-280° C. was employed.The screw speed was 350 rpm, and the feeding rate was 12 kg per hour.

The extrudates obtained were pelletized in pelletizer 750/3 (AccrapacSystems Limited). The resultant pellets were dried in a circulating airoven at 120° C. for four hours and at 80° C. in a vacuum oven overnight.

The dried pellets were injection molded into test specimens usingAllrounder 500-150 (Arburg). The conditions of the injection molding areset out in Table 2.

TABLE 2 PARAMETER UNITS Set values T₁ (Feeding zone) ° C. 265 T₂ ° C.270 T₃ ° C. 275 T₄ ° C. 280 T₅ (nozzle) ° C. 285 Mold temperature ° C.85 Injection pressure bar 1200 Holding pressure bar 500 Back pressurebar 80 Holding time sec 2 Cooling time sec 13 Filling volume ccm 19(portion) Injection speed ccm/sec 35 Switch over point [ccm] 12

The specimens produced were conditioned at 23° C. for a week and werethen subjected to a series of tests. The compositions produced and theresults of the tests are set out in Table 3.

TABLE 3 Examples and FR used Example 5 Example 6 (comparative)(invention) Composition Polyamide 66 (P-50FL) 43.8 44.3 Glass fibers (GFChop Vantage 3660) 30.0 30.0 Flame retardant 19.5 (Brominatedpolystyrene FR-803P) Flame retardant 19.1 (Pentabromobenzyl-substitutedpolystyrene of Example 1) Sb₂O₃ (as M-0112; containing 80% 6.0 6.0Sb₂O₃) Antioxidant & heat stabilizer (Acrawax C) 0.2 0.2 Antioxidant &heat stabilizer (Irganox 0.2 0.2 B1171) Lubricant (calcium stearate) 0.20.2 Bromine (calculated wt %) 13.0 13.0 Sb₂O₃ (calculated wt %) 4.8 4.8properties Flammability test: UL-94 vertical burning test at 0.8 mmthickness Max flaming time (s) 1 1 Total flaming time (s) 10 10 Numberof specimens dripped 5 5 Number of specimens igniting cotton 0 0 UL 94Rating V-0 V-0 Mechanical properties Izod notched impact (J/m) 96 97Tensile strength (MPa) 149 137 Tensile modulus (MPa) 10462 10450elongation at break (%) 3.7 3.5

The results set out in Table 3 indicate thatpentabromobenzyl-substituted polystyrene and commercial brominatedpolystyrene show equally good performance as flame retarding agents inpolyamide. The flammability and mechanical properties of the exemplifiedpolyamide formulations are comparable.

Example 7-8 (Comparative) and Example 9 (of the Invention) V-0 RatedTalc-Free Polypropylene Formulations

Pentabromobenzyl-substituted polystyrene of Example 1 was tested toevaluate its ability to reduce the flammability of polypropylenecopolymers (talc-free). For the purpose of comparison, two correspondingformulations was prepared, using decabromodiphenyl ethane andpoly(pentabromobenzyl acrylate) as flame retarding agents (FR-1410 andFR-1025, respectively; both are commercially available from ICL-IP).Materials used for preparing the compositions are tabulated in Table 4.

TABLE 4 Material (manufacturer) GENERAL DESCRIPTION FUNCTION PP CapileneSL-50 polypropylene impact copolymer plastic matrix (Caol) FR 1410decabromodiphenyl ethane FR FR 1025 poly(pentabromobenzyl acrylate FRProduct of pentabromobenzyl-substituted FR Example 1 polystyrene M0112Antimony trioxide masterbatch FR synergist (Kafrit) which contains 80%by weight Sb₂O₃ Irganox B 225 50% tris(2,4-ditert- Antioxidant & (Ciba)butylphenyl)phosphite and 50% heat stabilizer. pentaerythritoltetrakis[3-[3,5-di- tert-butyl-4- hydroxyphenyl]propionate]

Preparation of Polypropylene Compositions and Test Specimens

The compounding was performed in a twin-screw co-rotating extruder ZE25with L/D=32. Temperature profile of 120-180-200-200-200-210-220-230° C.was employed. The screw speed was 350 rpm, and the feeding rate was 12kg per hour.

The extrudtaes produced were pelletized in a pelletizer 750/3 fromAccrapak Systems Ltd. The resultant pellets were dried in a circulatingair oven at 80° C. for 3 hours. The dried pellets were injection moldedinto test specimens (1.6 mm thick) using Allrounder 500-150 from Arburgas tabulated in Table 5.

TABLE 5 PARAMETER UNITS Set values T₁ (Feeding zone) ° C. 210 T₂ ° C.215 T₃ ° C. 220 T₄ ° C. 225 T₅ (nozzle) ° C. 230 Mold temperature ° C.35 Injection pressure bar 1300 Holding pressure bar 600 Back pressurebar 60 Holding time sec 7 Cooling time sec 13 Filling volume (portion)ccm 38 Injection speed ccm/sec 35

The specimens were conditioned for one week at 23° C., and weresubjected to a set of tests. The results are shown in Table 7.

TABLE 7 Example 7 8 9 (comparative) (comparative) (invention)Composition (by weight %) Polypropylene 57.4 57.4 60 FR 1410 28 FR 102528 product of Example 1 27.9 Sb₂O₃ (as M-0112; 14.4 14.4 11.9 containing80% Sb₂O₃) Irganox B 225 0.2 0.2 0.2 Br content, % calculated 22 20 19.0Sb₂O₃, % calculated 11.5 11.5 9.5 Properties Flammability test: UL-94vertical burning test at 1.6 mm thickness Maximal flaming time 6 8 9(sec) Total Flaming time (sec) 17 47 63 Maximal glow time + 25 35 3second flaming (sec) Number of specimen 5 5 5 Number of Specimens 4 0 5dripped Number of cotton 0 0 0 ignition Rating V-0 V-0 V-0 MechanicalProperties Impact strength (J/m) 34 29 44 Tensile strength (MPa) 21 2420 Elongation at break (%) 46 7 61 Tensile modulus (MPa) 2010 1725 1478Other properties HDT (° C.) 58 85 62 MFI (gr/10 min) 4.8 7.7 4.12

The results show that pentabromobenzyl-substituted polystyrene issuccessfully added to polypropylene copolymer at a relatively lowconcentration in comparison to other bromine-containing flame retardingagents, to pass the UL-94 V-0 flammability test.Pentabromobenzyl-substituted polystyrene of the invention is able toachieve UL-94 V-0 rating in polypropylene copolymers at a brominecontent of 19% by weight, with the aid of 9.5% by weight antimonytrioxide. The comparative brominated flame retardants tested requirehigher bromine and antimony trioxide loading to impart UL-94 V-0 ratingto polypropylene copolymers.

Examples 10-12 (of the Invention) V-1 Rated Talc-ContainingPolypropylene Formulations

The aim of this set of examples is to evaluate the ability ofpentabromobenzyl-substituted polystyrene of Example 1 to reduce theflammability of talc-containing polypropylene formulations.

Ingredients used to Prepare the Compositions

The materials used for preparing the polypropylene compositions aretabulated in Table 8.

TABLE 8 Component (manufacturer) GENERAL DESCRIPTION FUNCTION PPCapilene polypropylene impact copolymer plastic SL-50 (Caol) matrixProduct of Pentabromobenzyl-substituted FR Example 1 polystyrene M0112Antimony trioxide masterbatch which FR synergist (Kafrit) contains 80%by weight Sb₂O₃ Talc MB Talc masterbatch of IOTALC Filler (Kafrit)IOTALC Talc powder Filler Irganox B 225 50%tris(2,4-ditert-butylphenyl)phosphite Antioxidant (Ciba) and 50%pentaerythritol tetrakis[3-[3,5-di- & heattert-butyl-4-hydroxyphenyl]propionate] stabilizer.

Preparation of Polypropylene Compositions and Test Specimens

The ingredients were compounded in a twin-screw co-rotating extruder(Berstorff ZE25) with L/D=32. Temperature profile of120-180-200-200-200-210-220-230° C. was employed. The screw speed was350 rpm, and the feeding rate was 12 kg per hour.

The extrudates produced were pelletized in a pelletizer 750/3 fromAccrapak Systems Ltd. The resultant pellets were dried in a circulatingair oven at 80° C. for 3 hours.

The dried pellets were injection molded into test specimens usingAllrounder 500-150 from Arburg according to the parameters set out inTable 9.

TABLE 9 PARAMETER UNITS Set values T₁ (Feeding zone) ° C. 210 T₂ ° C.215 T₃ ° C. 220 T₄ ° C. 225 T₅ (nozzle) ° C. 230 Mold temperature ° C.35 Injection pressure bar 1300 Holding pressure bar 600 Back pressurebar 60 Holding time sec 7 Cooling time sec 13 Filling volume (portion)ccm 38 Injection speed ccm/sec 35

The specimens were conditioned for one week at 23° C., and were thentested. The compositions and the results of the tests are set out inTable 10.

TABLE 10 Example 10 11 12 Composition (by weight %) Polypropylene 59.655.8 49.2 product of Example 1 23.5 26.5 26.5 Sb₂O₃ (as M-0112;containing 80% Sb₂O₃) 6.7 7.5 7.5 IOtalc 10.0 10.0 Talc masterbatch 16.7Irganox B 225 0.2 0.2 0.2 Bromine content, % calculated 16 18 18.0Antimony trioxide, % calculated 5.3 6.0 6.0 Talc, % calculated 10 10 10Properties Flammability test: UL-94 vertical burning test at 1.6 mmthickness Maximal flaming time (sec) 16 19 15 Total Flaming time (sec) —73 67 Maximal glow time + second flaming 0 6 28 Number of specimen 2 5 5Number of Specimens dripped 2 5 5 Number of cotton ignition 2 0 0 RatingV-2 V-1 V-1 Mechanical Properties Impact strength (J/m) ND 32 35 Tensilestrength (MPa) ND 21 18 Elongation at break (%) ND 30 55 Tensile modulus(MPa) ND 1924 1616 Other properties HDT (° C.) ND 62 57 MFI (g/10 min)ND 3.45 3.08

1. A process for preparing bromine-containing polymers, comprising aFriedel-Crafts alkylation reaction of pentabromobenzyl halide with apolymer reactant having one or more six-membered aromatic ring(s) in itsrepeat unit, wherein said reaction takes place in a solvent in thepresence of at least one Friedel-Crafts catalyst.
 2. A process accordingto claim 1, wherein the pentabromobenzyl halide is pentabromobenzylbromide.
 3. A process according to claim 1, wherein the polymer startingmaterial is represented by Formula III or Formula IV:

wherein in Formula III, R is a linear or branched aliphatic chain orbromine; k is independently an integer from 0 to 4; A is selected fromthe group consisting of null, —CH₂CH₂—, —CH₂CH═CHCH₂—, —CH(CH₃)CH₂— and—CH₂—CH═C(CH₃)CH₂—; n and m are the number of units in the polymerchain; and wherein in Formula IV, X is selected from the groupconsisting of null, O, S, —CH₂—, —CH₂CH₂—, and n is the number of unitsin the polymer chain.
 4. A process according to claim 3, wherein thepolymer starting material is either a polymer of Formula III, with k=0,A=null and m=0 (polystyrene) or a polymer of Formula IV, with X═O(poly(phenylether)).
 5. A process according to claim 4, comprisingcharging a reaction vessel with a solvent, a polymer starting materialwhich is polystyrene, pentabromobenzyl halide and one or more catalystsused for Friedel-Crafts alkylation, allowing the Friedel-Craftsalkylation to reach completion and recovering bromine-containingpolystyrene having pendent —CH₂C₆Br₅ groups.
 6. A process according toclaim 1, wherein a mixture of AlCl₃ and SnCl₄ is used to catalyze thereaction.
 7. A process according to claim 1, further comprising a stepof subjecting the so-formed pentabromobenzyl-substituted polymer tobromination reaction.